Elements of Mechanical Engineering, 21ME15
ELECTROCHEMICAL MACHINING (ECM`)
• The electrolyte is pumped to the work region by means of a pump(pumps electrolyte
from the tank to other parts) through a filter(removes impurities present in the
electrolyte), pressure gauge(indicates the pressure of electrolyte coming from the pump),
flow meter(measures the discharge rate of the electrolyte) and finally, it enters into the
work region.
• An optimum gap is maintained between the tool and the workpiece. As the electrolyte
reaches the gap between anode and cathode, electrical contact is established between the
anode and the cathode
• Based on the principle of electrolysis, the positive ions from the workpiece are dissolved
and carried away by the electrolyte thus stopping it from reaching the tool and negative
ions start flowing from the tool towards the workpiece
• Chemical reaction taking place during electrochemical machining,
2H+ + 2e- = H2
Department of Mechanical Engineering, SCEM Page 1
, Elements of Mechanical Engineering, 21ME15
Fe = Fe++ + 2e-
Na++OH- = NaOH
Fe2++2Cl- = FeCl2
• Material removal process from the workpiece is continued until a cavity is created in the
workpiece which is a replica of the tool used in this process.
• Material is removed from the workpiece and gets settled down in the form of a slug,
which is due to the flow of electrolytes.
• The electrolyte then goes through a filtration process. In the filtration process, the
electrolyte is passed through a centrifuge where the slug is removed.
ADVANTAGES
• Suitable for hard materials
• Negligible stresses
• No heat produced
• No tool wear as there is no contact between tool and workpiece
DISADVANTAGES
• Higher cost
• Limited materials – good conductors
• Workpiece get corroded due to electrolyte
APPLICATIONS
• Used for machining hard materials
• Used for micromachining
• Used for machining turbine blades
Department of Mechanical Engineering, SCEM Page 2
ELECTROCHEMICAL MACHINING (ECM`)
• The electrolyte is pumped to the work region by means of a pump(pumps electrolyte
from the tank to other parts) through a filter(removes impurities present in the
electrolyte), pressure gauge(indicates the pressure of electrolyte coming from the pump),
flow meter(measures the discharge rate of the electrolyte) and finally, it enters into the
work region.
• An optimum gap is maintained between the tool and the workpiece. As the electrolyte
reaches the gap between anode and cathode, electrical contact is established between the
anode and the cathode
• Based on the principle of electrolysis, the positive ions from the workpiece are dissolved
and carried away by the electrolyte thus stopping it from reaching the tool and negative
ions start flowing from the tool towards the workpiece
• Chemical reaction taking place during electrochemical machining,
2H+ + 2e- = H2
Department of Mechanical Engineering, SCEM Page 1
, Elements of Mechanical Engineering, 21ME15
Fe = Fe++ + 2e-
Na++OH- = NaOH
Fe2++2Cl- = FeCl2
• Material removal process from the workpiece is continued until a cavity is created in the
workpiece which is a replica of the tool used in this process.
• Material is removed from the workpiece and gets settled down in the form of a slug,
which is due to the flow of electrolytes.
• The electrolyte then goes through a filtration process. In the filtration process, the
electrolyte is passed through a centrifuge where the slug is removed.
ADVANTAGES
• Suitable for hard materials
• Negligible stresses
• No heat produced
• No tool wear as there is no contact between tool and workpiece
DISADVANTAGES
• Higher cost
• Limited materials – good conductors
• Workpiece get corroded due to electrolyte
APPLICATIONS
• Used for machining hard materials
• Used for micromachining
• Used for machining turbine blades
Department of Mechanical Engineering, SCEM Page 2
